DE102019126347A1 - Manufacturing process for a high pressure tank - Google Patents

Abstract

A manufacturing process for a high pressure tank (10) includes making a liner (20) and forming a helical layer (34) by helically or biaxially winding fiber bundles (FB) around the liner (20), a plurality of layers (LI to L10) contained in the helical layer (34) includes: base reversal layers (L1, L2, L4, L5, L7, L8, L10) formed by winding the fiber bundles (FB) while a base portion (RS ) each of the caps (13, 14) protruding outward from the liner (20) is used as a winding reversal position at which the fiber bundles (FB) are reversed in the axial direction; and far inversion layers (L3, L6, L9), which are formed by winding the fiber bundles while a remote position (DS) distant from each base section (RS) is used as the winding inversion position, and in the far inversion layers (L3, L6, L9) the helical or biaxial winding is carried out in such a way that gaps are generated between adjacent fiber bundles of the fiber bundles.

Description

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to a manufacturing method for a high pressure tank.

Description of the prior art

Some liners contained in high pressure fuel gas storage tanks for natural gas cars, fuel cell cars, and the like have reinforcement layers to reinforce the outer surfaces of the liners (see FIGS WO 2016/020972 A1 ).

SUMMARY OF THE INVENTION

The WO 2016/020972 A1 describes a high-pressure tank with a tire layer or tire-shaped layer and a screw layer or screw-shaped layer as a reinforcing layer. In such a high-pressure tank, it is conceivable to reduce the amount of fibers forming the reinforcement layer in order to reduce the weight of the high-pressure tank. However, the stress or strain or elongation caused by the swelling or the volume increase of the lining in the reinforcement layer can be increased due to a reduction in the amount of fibers. In order to solve such a problem, technology has been required which achieves both the weight reduction of the high pressure tank and the reduction in the increase in the stress caused in the reinforcement layer due to the reduction in the amount of fibers.

The present invention can be implemented in the following aspects.

According to one aspect of the present invention, a manufacturing method for a high pressure tank is proposed. The manufacturing process for a high pressure tank includes: manufacturing a liner that defines a space configured to seal a gas in the space, the liner including a cylindrical portion in a cylindrical shape and a pair of dome portions located at both ends of the cylindrical portion are arranged in an axial direction of the cylinder section, caps being arranged on the respective dome sections; and forming a helical layer by helically winding biaxial bundles of fibers on the liner, wherein a plurality of layers contained in the helical layer include: base reversal layers formed by winding the bundles of fibers while a base portion of each of the caps which protrudes from the liner in the axial direction is used as a lap reversal position where the fiber bundles ( FB ) be reversed in the axial direction; and far inversion layers formed by winding the fiber bundles while a far position distant from each base portion is used as the winding inversion position, and in the far inversion layers, the helical winding is carried out so that there are gaps between adjacent fiber bundles of the fiber bundles.

With the above aspect, the weight reduction of the high pressure tank can be achieved. In addition, the stress caused in the reinforcing layer can be reduced compared to a high pressure tank with a helical layer formed only by the base reversal layers. In addition, in the distant reversal layers, it is possible to reduce the weight of the high pressure tank by forming gaps between the fiber bundles, and it is possible to further reduce the stress caused in the reinforcing layer as compared to the case without gaps.

In the aspect described above, the coverage with the far inversion layers can range from not less than 50% to not more than 80%.

With such a configuration, it is possible to achieve both the reduction in the amount of fibers and the reduction in the increase in stress caused in the reinforcement layer due to the reduction in the amount of fibers without unduly reducing the strength.

The present invention is not limited to the manufacturing method for a high-pressure tank, and can be applied to various types of a high-pressure tank manufactured by the above manufacturing method and a manufacturing device for a high-pressure tank and the like. Furthermore, the present invention is not limited to the aspects described above, and it need not be mentioned that the present invention can be carried out in various ways without departing from the scope of the present invention.

Figure list

• 1 eine Schnittansicht, die den schematischen Aufbau eines Hochdrucktanks zeigt;
• 2 ein Prozessdiagramm, das ein Herstellungsverfahren für den Hochdrucktank zeigt;
• 3 eine vergrößerte Ansicht, die die Umgebung einer Kappe zeigt;
• 4 eine erläuternde Ansicht, die eine schraubenförmige Wicklung mit niedrigem Winkel erklärt;
• 5 eine erläuternde Ansicht, die eine schraubenförmige Wicklung mit hohem Winkel erklärt;
• 6 eine vergrößerte Ansicht eines Teils einer Auskleidung, der mit Schichten mit einer Abdeckung von 80% bedeckt ist;
• 7 eine vergrößerte Ansicht eines Teils der Auskleidung, der mit Schichten mit einer Abdeckung von 100% bedeckt ist;
• 8 eine vergrößerte Ansicht der Umgebung der Kappe; und
• 9 eine vergrößerte Ansicht der Umgebung der Kappe.

The features and advantages as well as the technical and economic significance of exemplary embodiments of the invention are described below with reference to the accompanying drawings, in which like reference numerals designate like elements; here shows:

• 1 a sectional view showing the schematic structure of a high pressure tank;
• 2nd a process diagram showing a manufacturing process for the high pressure tank;
• 3rd an enlarged view showing the vicinity of a cap;
• 4th an explanatory view explaining a low-angle helical winding;
• 5 an explanatory view explaining a high-angle helical winding;
• 6 an enlarged view of a portion of a liner covered with layers with an 80% coverage;
• 7 an enlarged view of a portion of the liner covered with layers with a 100% coverage;
• 8th an enlarged view of the surroundings of the cap; and
• 9 an enlarged view of the area surrounding the cap.

DETAILED DESCRIPTION OF THE EMBODIMENTS

First embodiment

1 Fig. 12 is a sectional view showing a schematic configuration of a high pressure tank 10th shows, which was produced by the manufacturing method of the first embodiment. 1 shows XYZ axes that are orthogonal to each other. The XYZ axes in 1 correspond to the XYZ axes in the other drawings. In the high pressure tank 10th In the present embodiment, for example, a high pressure hydrogen gas of about 70 MPa is stored. The high pressure tank 10th includes a liner 20th and a reinforcement layer 30th .

The lining 20th is a hollow resin lining and forms a space for sealing a gas inside. The lining 20th consists for example of a thermoplastic resin such as polyethylene, nylon, polypropylene and polyester. A central axis of the liner 20th is equal to a central axis AX of the high pressure tank 10th . Below is a direction along the central axis AX as a direction of the central axis AX be designated. The lining 20th includes a cylinder section 21 , Dome sections 22 , 23 and caps 13 , 14 .

The cylinder section 21 has a cylindrical shape. The dome sections 22 , 23 are a pair at both ends of the cylinder section 21 in the axial direction of the cylinder section 21 arranged and each formed in a curved surface shape that leads to the outside of the lining 20th is convex. On the top of the dome sections 22 , 23 are caps 13 , 14 arranged from metal such as aluminum and stainless steel. The cap 13 has a through hole on one side 15 and serves to fill the high pressure tank 10th with the gas or to discharge the gas from inside the high pressure tank 10th . The cap 14 on the other hand serves to rotate the liner while the liner is being reinforced 20th or forming the reinforcement layer of the liner 20th .

The reinforcement layer 30th are layers covering the outer circumference of the liner 20th cover and to reinforce the lining 20th serve. The reinforcement layer 30th includes a tire layer 32 and a screw layer 34 .

The tire-shaped layer 32 is achieved by winding fiber bundles around the cylinder section in the form of a tire 21 configured around. The fiber bundles used for the tire-shaped winding consist of fiber bundles made of carbon fibers, which are impregnated with a thermosetting resin, such as an epoxy resin.

The helical layer 34 is done by helically winding fiber bundles on the tire-shaped layer 32 and the dome sections 22 , 23 configured. The fiber bundles used for the helical winding consist, like the fiber bundles used for the tire winding, of fiber bundles made of carbon fibers, which are impregnated with a thermosetting resin such as epoxy resin.

The thickness of the tire-shaped layer 32 and the thickness of the helical layer 34 corresponding to a pressure resistance and one for the high pressure tank 10th required strength set.

2nd is a process diagram showing the manufacturing process for the high pressure tank 10th shows. In the manufacturing method of the present embodiment, there is first a preparatory step for manufacturing the liner 20th carried out (step P110 ). The caps 13 , 14 are at the respective tips of the dome sections 22 , 23 of the lining being prepared at that time 20th arranged.

After the preparatory step (step P110 ) a tire layer formation step is carried out so that the tire-shaped layer 32 by winding the fiber bundles around the cylinder section in the form of a tire 21 (Step P120 ) is formed.

After the tire film formation step (step P120 ) a screw layer formation step is carried out so that the helical layer 34 by helically winding the fiber bundles onto the tire-shaped layer 32 and the dome sections 22 , 23 is formed (step P130 ). After the screw layer formation step (step P130 ) is the high pressure tank 10th completed (see 1 ). The reinforcement layer may be in the reverse order of the tire layer formation step (step P120 ) and the screw layer formation step (step P130 ) are formed. In this case, the tire-shaped layer 32 on the helical layer 34 formed on the cylinder section 21 was formed.

3rd is an enlarged view of the vicinity of the cap 14 . The helical layer 34 includes a plurality of layers L1 to L10 . A reference symbol x in a layer Lx (x is an integer from 1 to 10th ) denotes an xth layer from the side of the dome section 23 in the helical layer 34 is formed. The layer L1 is a layer created by helically winding the fiber bundle on the outer peripheral surface of the liner 20th is formed. The layer L2 is a layer created by helically winding the fiber bundle onto the layer L1 is formed. The layer L1 and the layer L2 are formed by a helical winding with a low angle.

4th Fig. 10 is an explanatory diagram for explaining the low-angle helical winding. 4th shows how the fiber bundle FB thanks to the helical winding with a low angle around the lining 20th be wrapped. The "helical winding with low angle" is a winding process with a relatively small winding angle α where the fiber bundle FB in the winding of the fiber bundle FB in the direction of the central axis AX is reversed before the fiber bundle FB around a lap around the central axis AX in the cylinder section 21 be wrapped. In the present embodiment, the wrap angle is α 30 degrees. In the low-angle helical winding, the winding reversal positions correspond to where the fiber bundle FB in the direction of the central axis AX be reversed, the basic sections RS (shown in 1 ), the curved surface sections CS that continue with the dome sections 22 , 23 the caps 13 , 14 are formed, and respective projecting sections PS the caps 13 , 14 running along the direction of the central axis AX from the high pressure tank 10th stick out, connect. In other words, the winding reversal positions in the low-angle helical winding are the base portions RS the caps 13 , 14 the lining 20th running along the direction of the central axis AX out of the lining 20th protrude outwards.

The layer L3 is a layer created by helically winding the fiber bundle onto the layer L2 is formed. The layer L3 is formed by a helical winding with a high angle.

5 Fig. 10 is an explanatory view for explaining the helical winding at a high angle. 5 shows how the fiber bundle FB thanks to the helical winding at a high angle around the lining 20th be wrapped. The "helical winding with a high angle" is a winding process with a relatively large winding angle β where the fiber bundle FB in the direction of the central axis AX in the winding of the fiber bundle FB be reversed after the fiber bundle FB by at least one lap around the central axis AX in the cylinder section 21 were wrapped.

In the present embodiment, the wrap angle is β 60 degrees. It can be said that the "high angle helical winding" is a winding process in which the fiber bundle FB in the winding of the fiber bundle FB not in the direction of the central axis AX be turned back before the fiber bundle FB around a lap around the central axis AX in the cylinder section 21 be wrapped. In the helical winding with a high angle, the winding reversal positions correspond to those in which the fiber bundles FB in the direction of the central axis AX be reversed, the remote positions DS by the previous sections PS the caps 13 , 14 of the dome sections 22 , 23 are removed (shown in 1 ). In other words, the winding reversal positions of the "high-angle helical winding" are those of the base portions RS , ie the winding reversal positions of the "helical winding with a low angle", remote positions distant in the Z-axis direction DS . In 1 is the remote position DS on the curved surface of the dome section 23 arranged, but can also on a curved surface section CS the cap 14 lie.

The layer L4 , the layer L5 , the layer L7 , the layer L8 and the layer L10 are formed by the low-angle helical winding, as in the layer L1 and the layer L2 . The layer L6 and the layer L9 become like the shift L3 formed by the helical winding at a high angle. In the present embodiment, the layers formed by the low-angle helical winding correspond to the base reversal layers. In the present embodiment, the layers formed by the high-angle helical winding correspond to the far inversion layers.

With those in the shift L3 , the layer L6 and the layer L9 contained fiber bundles, the helical winding is carried out so that a gap or a gap between adjacent fiber bundles of the fiber bundles in each layer. A cover with the fiber bundles of the layer L3 , the layer L6 and the layer L9 is 80%.

6 is an enlarged view of part of the liner 20th which is covered with layers with a coverage of 80%. Hatched sections in 6 show surface portions of the liner 20th that are not with the fiber bundles FB are covered.

7 is an enlarged view of part of the liner 20th that is covered with layers with a coverage of 100%. 7 shows a state in which the liner 20th is not visible since the lining 20th all over with the fiber bundles FB is covered.

Like the cover when forming the helical layer 34 is set with reference to 6 described. In 6 is in two considered adjacent fiber bundles when a distance from one end in the width direction of one fiber bundle and one end in the width direction of the other fiber bundle as width P coverage is defined as a percentage of a distance L defined from one end to the other end in the width direction of the one fiber bundle relative to the width.

8th is an enlarged view of the vicinity of the cap 14 a high pressure tank 10a made by the manufacturing process of a comparative example 1 was produced. The configuration of the high pressure tank 10a of the comparative example 1 is the same as that of the high pressure tank 10th made by the manufacturing method of the first embodiment, except that the high pressure tank 10a a helical layer 34a has, which is from the helical layer 34 differs.

The helical layer 34a includes a plurality of layers La1 to La10 . A reference symbol y of a layer Lay (y is an integer of 1 to 10th ) denotes a yth layer from the side of the dome section 23 in the helical layer 34a is formed. Layers La1 to La10 are formed by a low angle helical winding. Coverage with the layer La1 to La10 is 100%.

In the low-angle helical winding, the winding reversal positions of the fiber bundles are at the base portions RS so that the winding of the fiber bundle is close to the base sections RS concentrated. Hence it comes in the sections PR the helical layer 34a that on the base sections RS are formed, to a local swelling or a local increase in volume. With such a high pressure tank 10a it was confirmed that a strain of 2.17% in the reinforcement layer 30th occurs when the tank is filled with the gas with an amount that is sufficient for the lining 20th has an internal pressure of 180 MPa. The elongation or stress referred to here means any displacement, expansion, contraction, torsion, linear elongation or surface elongation or any other deformation in a part of the reinforcement layer. If a state in which there is no stretch in the reinforcement layer 30th is caused as 0% is defined by the strains caused by the increase in the internal pressure of the liner 20th caused from this condition, an elongation in a part where maximum elongation is caused is defined as a measurement value. In addition, the stresses caused in the reinforcement layer are determined by calculations based on a simulation with CAE (CAE = computer aided engineering).

9 is an enlarged view of the vicinity of the cap 14 in a high pressure tank 10b made by the manufacturing process of a comparative example 2nd was produced. The configuration of the high pressure tank 10b of the comparative example 2nd is the same as that of the high pressure tank 10th made by the manufacturing method of the first embodiment, except that the high pressure tank 10b a helical layer 34b has, which is from the helical layer 34 differs.

The helical layer 34b includes a plurality of layers Bb1 to Bb10 . A reference number z of a layer Lbz (z is an integer from 1 to 10) denotes a zth layer from the side of the dome portion 23 in the helical layer 34b is formed. The layers Bb1 , Bb2 , Bb4 , Bb5 , Bb7 , Bb8 , Bb10 are formed by the low angle helical winding. The layers Bb3 , Bb6 , Lb9 are formed by the helical winding at a high angle. The helical layer 34 the first embodiment and the helical layer 34b of the comparative example 2nd have the same configurations as the first, second, fourth, fifth, seventh, eighth and tenth layers from the side of the dome portion 23 are formed, and are formed by the low-angle helical winding, and the third, sixth, and ninth layers by the side of the dome portion 23 is formed, will be formed by the helical winding at a high angle. A difference between the helical layer 34 the first embodiment and the helical layer 34b of the comparative example 2nd is that in the comparative example 2nd the coverage with the layers formed with the high angle helical winding is 100%.

In the case of the manufacturing method of the comparative example 2nd manufactured high pressure tank 10b becomes the concentration of the winding of the fiber bundles in the vicinity of the base sections RS suppressed more than that of the manufacturing method of the comparative example 1 manufactured high pressure tank 10a ; hence it comes in on every base section RS the helical layer 34b formed section PR hardly to a local swelling or a local volume increase. It is believed that this is due to the layers Bb3 , Bb6 , Lb9 formed by the helical winding at a high angle. However, since in the high angle helical winding, the winding reversal positions of the fiber bundles differ from those of the above sections PS the caps 13 , 14 of the dome sections 22 , 23 distant remote positions DS the winding of the fiber bundles is close to the remote positions DS concentrated. Therefore, that occurs after the manufacturing process of the comparative example 2nd manufactured high pressure tank 10b a local swelling in the section PD the helical layer 34b that at any remote position DS is formed on that smaller than the section PR . With such a high pressure tank 10b it was confirmed that if the tank is filled with the gas with an amount sufficient for the lining 20th has an internal pressure of 180 MPa, an elongation of 1.68% in the reinforcement layer 30th occurs.

On the other hand, in the high pressure tank manufactured by the manufacturing method of the first embodiment 10th the layers L1 L2 , L4 , L5 , L7 , L8 , L10 formed by the low angle helical winding. The layers L3 , L6 , L9 are formed by the helical winding at a high angle. In addition, the coverage with the layers is L3 , L6 , L9 formed by the high angle helical winding, 80%.

Compared to that after the manufacturing process of the comparative example 1 manufactured high pressure tank 10a with the helical layer 34a comprising the layers formed by the low-angle helical winding is used in the high-pressure tank manufactured by the manufacturing method of the first embodiment 10th the concentration of the winding of the fiber bundles in the vicinity of the base sections RS suppressed. Therefore, it is unlikely that there will be a local swelling or local volume increase in the section PR the helical layer 34 that comes on every base section RS is trained. In addition, compared to that of the manufacturing method of the comparative example 2nd trained high pressure tank 10a which has 100% coverage with the layers formed by the high angle helical winding in the high pressure tank 10th made by the manufacturing method of the first embodiment, the cover with the layers formed by the helical winding at high angle, 80%. Hence it comes in the section PD the helical layer 34 at any remote position DS is hardly formed to a local swelling or a local increase in volume. With such a high pressure tank 10th it was confirmed that an elongation of 1.58% in the reinforcement layer 30th occurs when the tank is filled with the gas with an amount that is sufficient for the lining 20th has an internal pressure of 180 MPa.

At the high pressure tank 10th are the layers formed by the helical winding at a high angle in the helical layer 34 included, thereby causing local swelling in the section PR to suppress that at the high pressure tank 10a of the comparative example 1 occurs. Furthermore, the high pressure tank 10th the cover with the layers formed by the helical winding at a high angle was set to 80% so as to cause local swelling in the sections PD to suppress that in the high pressure tank 10b of the comparative example 2nd occurs. In other words, the high pressure tank 10th it is possible because of the shape of the helical layer 34 is formed in a smooth form by suppressing the occurrence of a local swelling or a local increase in volume, the occurrence of bends in the in the helical layer 34 to suppress contained fiber bundles and a difference in rigidity between the multiple layers in the helical layer 34 to reduce. Accordingly, it is possible to use the in the reinforcement layer 30th to reduce generated strain or stress.

According to the embodiment described above, the weight reduction of the high pressure tank 10th can be achieved. In addition, compared to that of the manufacturing method of the comparative example 1 manufactured high pressure tank 10a suppresses the stress caused in the reinforcement layer more. In addition, it is compared to that after the manufacturing process of the comparative example 2nd manufactured high pressure tank 10b possible to reduce the weight of the high pressure tank 10th to achieve because the cover is smaller and gaps are formed between the fiber bundles. Furthermore, the in the reinforcement layer 30th caused stress against the high pressure tank 10b with the gap-free helical layer 34a made by the manufacturing method of the comparative example 2nd is produced, further reduced.

In addition, it is with the high pressure tank 10th possible, since the coverage with the layers formed by the high-angle helical winding is 80%, without achieving both the reduction in the amount of fiber and the increase in the stress caused in the reinforcing layer due to the reduction in the amount of fiber reduce the strength excessively.

Other embodiments

In the above-described embodiments, the coverage with the layers formed by the high-angle helical winding is 80%, but the present invention is not limited to this. By reducing the cover to less than 80% it is possible to further reduce the weight of the high pressure tank 10th and to reduce the load on the reinforcement layer. If the coverage rate is reduced too much, the reinforcement layer can 30th that the lining 20th reinforced, insufficient strength can be achieved. Taking these points into account, the covering with the layers formed by the helical winding at a high angle can be set to any value selected from a range of at least 50% to at most 80%, as far as the reinforcement of the lining 20th and the reduction in the reinforcement layer 30th caused stretch are compatible.

In the embodiment described above, 30% of the majority in the helical layer 34 Contained layers formed by the high-angle helical winding, but the present invention is not limited to this. The ratio of the layers formed by the high-angle helical winding to the majority of those in the helical layer 34 contained layers, can be chosen in a suitable manner, as far as the reinforcement of the lining 20th and the reduction in the reinforcement layer 30th caused stretch are compatible.

The present invention is not limited to the embodiments, examples, and modifications described above, and can be implemented in various configurations without departing from the scope of the invention. For example, the technical features in the embodiments, examples, and modifications that correspond to the technical features in the aspects described in the "Summary of the Invention" section may be replaced or combined to solve some or all of the problems described above or in part or to achieve all of the above effects. If the technical features are not described as essential in the present specification, they can optionally be omitted.

QUOTES INCLUDE IN THE DESCRIPTION

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Patent literature cited

• WO 2016/020972 A1 [0002, 0003]

Claims (2)

Manufacturing process for a high pressure tank (10), comprising: Producing a liner (20) forming a space configured to seal a gas in the space, the liner including a cylindrical portion (21) in a cylindrical shape and a pair of dome portions (22, 23) on both Ends of the cylinder section (21) are arranged in an axial direction of the cylinder section (21), caps (13, 14) being arranged on the respective dome sections (22, 23); and Forming a helical layer (34) by helically winding fiber bundles (FB) on the lining (20), wherein a plurality of layers (L1 to L10) contained in the helical layer (34) include: base reversal layers (L1, L2, L4, L5, L7, L8, L10) formed by winding the fiber bundles (FB) while a base portion (RS) of each of the caps (13, 14) protruding axially from the liner (20) is used as a winding reversal position at which the fiber bundles (FB) are reversed in the axial direction; and far inversion layers (L3, L6, L9) formed by winding the fiber bundles (FB) while using a far position (DS) distant from each base section (RS) as the winding inversion position, and in the remote reversal layers (L3, L6, L9) the helical winding is carried out in such a way that gaps are formed between adjacent fiber bundles of the fiber bundles (FB). Manufacturing process for a high pressure tank Claim 1 A coverage with the fiber bundles (FB) of the far-inversion layers (L3, L6, L9) is in a range from not less than 50% to not more than 80%.

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